MCP2xxx Dual Channel Motor Controller

Transcription

1 MCP2xx3, 34VDC Dual Channel MCP2xx6, 60VDC Dual Channel MCP2xx8, 80VDC Dual Channel Programmable Brushed DC Motor Controller (c) 2015 Ion Motion Control. All Rights Reserved.

2 Feature Overview: 120 / 160 / 200 Amps per channel for two brushed DC motors 240 / 320 / 400 Amps in bridged channel mode for one brushed DC motor Dual quadrature encoder inputs with hardware 32-Bit counters Programmable with built-in user scripting language Minimum of 100,000 instructions per second execution speed 128Kb Flash available for user scripting programs 16Kb Ram available for user scripting programs 1Kb Non-Volatile memory for storage by user scripting programs USB, RS232, TTL, R/C, PWM and Analog control modes Automatic control switching with user defined priority settings Input control mixing Data Logging Diagnostic LEDs for easy in field diagnostics Field Firmware Updates OpenCAN master or slave support I2C Interface for use with sensor such as gyros, accelerometers, temperature and displays Up to 11 Analog inputs for control, encoder feedback or as user script controlled inputs Up to 13 PWM inputs for control, encoder feedback or as user script controlled inputs Up to 20 Digital inputs for limit switches, emergency stops, homing or as user script controlled inputs 8 General purpose 40V, 1Amp user controlled outputs for driving relays, brakes or contactors User programmable input triggers with minimum and maximum range settings Regulated 5VDC, 3A output (BEC) for powering external devices such as sensors or controllers like Arduino, Rasberry Pi Up to 80VDC versions available Fully enclosed for protection Conduction plate and top side heat mangement for high performance cooling 3.3v Compliant outputs for safe interfacing with controllers such as Rasberry Pi 15v Tolerant inputs for interfacing to industrial devices such as PLCs Overvoltage and under voltage protection monitoring Programmable current limiting Auto tune PID for fast encoder and motor setup PC utility included for fast setup and tunning Device Overview The MCP motor controller is a high power, high performance rugged motor controller built to withstand the most demanding applications. It incorporates a built-in scripting language with advance motion control. At the heart is a 32Bit high performance Cortex M4 processor with DSP and FPU. The user programmable feature allows the MCP to be customized for any application. It can interface with several communication standards in addition to including several user configurable I/O. The MCP can be used as a standalone controller with out the need for an additional processor therefore reducing over all design cost and system complexity. At the heart of the MCP motor controller is a high performance motion control intelligence which achieves high precision control and optimum motor performance in open or closed loop modes. Close loop mode supports dual quadrature encoders with up to 21 million PPS. Close loop mode creates absolute control over speed, velocity and direction regardless of loading changes. In addition, a wide range of sensor inputs including potentiometers and absolute encoders are supported. Multimode Interface The MCP supports several types of control input. USB, R/C Pulse, Analog, TTL, RS232 and CAN are supported. Control can be setup to auto switch from one interface to another. The MCP can be configured as a master or slave in a CAN network. In addition several user controllable I/O are available for setting up limit switches, sensors, E-stops and more. The MCP includes 2 user controllable general purpose 40V at 1Amp I/O for controlling brakes, contactors and other high load devices. Protection The MCP utilizes high precision temperature, current and voltage sensing to monitor conditions and ensure safe and reliable operations. The peak operational voltage depending on model can be up to 80VDC. MCP is a regenerative motor controller. During regeneration, voltages can peak over 80VDC. MCP is designed to handle well over 100VDC voltage spikes and is not rated to its absolutely maximum operating specifications which provides a safe and reliable operating margin. Software IonMotion is a free PC utility configuration tool used to setup, configure and monitor the MCP. The software can be used during run time to monitor and control several operational parameters. IonMotion is also the interface for customizing the built-in motion control language. (c) 2015 Ion Motion Control. All Rights Reserved. 2

3 Hardware Overview: H G F I TOP VIEW E D C B A SIDE VIEW I J FRONT VIEW J A B C D E A: Status LEDs. B: USB Port. C: Control Input. D: Encoder Input. E: Digital Ouput. F: Motor Channel 1. G: Main Battery Input. H: Motor Channel 2. I: Air Cooling. J: Conduction Cooling. (c) 2015 Ion Motion Control. All Rights Reserved. 3

4 Important Notices The following information is required for safe and reliable operation. It is up to the user to ensure the following criteria is met. Several external factors can influence how the MCP operates. Following basic safety procedures can prevent dangerous situations. Warnings The following guidelines should be followed when using the MCP or damage will occur. There are several factors that will affect the operation of the MCP. 1. Battery wire should be no longer than 20 inches in length. 2. Motor wire should be no longer than 20 inches in length. 3. DO NOT overload the BEC. Logic power is drawn from the same source and brownouts can occur. 4. DO NOT reverse the battery polarity. Damage will result. 5. ALWAYS Incorporate an emergency main battery cut off switch. 6. Cut off should always be on the positive (+) of power to prevent ground loops. 7. Power diode, fuse and pre charge resistor should be added to all power switch circuits. 8. DO NOT get the MCP wet and avoid high moisture environments without proper moisture control. Mounting The MCP will generate heat. The controller should be mounted to a metal surface that will conduct the heat away from the MCP during operation. The maximum amperage ratings can only be achieved and maintained with adequate heat dissipation. Emergency Stop MCP should be wired using an external contactor or relay to ultimately control the main power input. A second power source should be used to power the logic section in situations where the main power will be under heavy load. Voltage level drops can occur from constant full load or full speed direction changes and can potential cause logic brown outs. USB The MCP USB port can be used for configuration and debugging. The USB protocol is not meant for electrically noisy environments. The USB port can potentially drop out during operation and may not recover without unplugging and plugging in the MCP. In high electrical noise environment RS232 should be used. CAN Bus The MCP can interface to a CAN bus using CANOpen protocol. The MCP supports the DS402 profile for motion control devices. The MCP can be a master or slave device on the bus. CAN is available when the MCP is plugged into the USB. The MCP can be used as a master interface to control other MCPs over the a CAN bus. I2C The I2C bus can be used to communicate to any compatible I2C device. The I2C devices can be controlled by a user program. The MCP can be easily interfaced to devices such as Gyro and Accelerometers for standalone applications. Firmware Updates From time to time new firmware updates will be available to add new features or resolve an issue. It is recommended to update to the latest firmware during development. Firmware updates are handled by the IonMotion PC utility. IonMotion is free to download from Ionmc.com. Once IonMotion is installed, connect the motor controller to your computer running Windows 7 or newer. Once IonMotion is launched it will detect the attached motor controller and attempt to first download the latest firmware from Ionmc.com before updating. User Regulated Power (BEC) The MCP motor controllers provides a user power source typically referred to as a battery elimination circuit or BEC. This regulated supply provides power to user electronics and sensors. It eliminates the need for secondary battery sources due to high input voltages from the main power source. The BEC circuit is not monitored. The logic control circuits of the motor controller are supplied from the same switching regulator circuit. If maximum current is exceed the switching regulators built in thermal protection circuitry will activate causing a system wide brown out. (c) 2015 Ion Motion Control. All Rights Reserved. 4

5 Control Interface (CTRL) The MCP motor controllers use minature Molex connectors. The following tables list the pins and their functions. Most all pins are 15V tolerant and output 3.3V for compatibility with processor such as Rasberry Pi and Arduino. CTRL pins are low side drivers at 40VDC, 1A per output. R/C pulse input, Analog and TTL can be generated from any microcontroller such as a Arduino or Rasberry Pi. The R/C Pulse in pins can also be driven by any standard R/C radio receiver. There are several user configurable options depending on the device used to control the motor contoller. To configure the motor controller connect it to a free USB port. Then install the IonMotion PC utility. USB MCP IONMC.COM ERR STAT1 STAT2 CTRL ENC DRV Mating Connector Part Number: Pin PWR DIN DOUT ANALOG PULSE ENCODER UART TTL UART RS232 CAN I2C 1 DIN1 RX1 SDA 2 GND 3 DIN2 TX1 SCL 4 +5V 5 DIN3 AN1 P1 6 DIN4 P2 HALL1 7 DIN5 AN2 P3 8 DIN6 P4 HALL2 9 DIN7 AN3 10 DIN8 P5 HALL3 11 DIN9 AN4 P6 12 DIN10 P7 13 DIN11 AN5 14 DIN12 TX3 15 DIN13 AN6 16 DIN14 RX3 17 DIN15 AN7 P8 18 TX0 CANH 19 DIN16 P9 20 RX0 CANL 21 GND 22 LB+ (c) 2015 Ion Motion Control. All Rights Reserved. 5

6 Encoders (ENC) RoboClaw supports dual quadrature encoders with up to 19.6 million pulses per second. In addition, a wide range of sensor inputs including potentiometers and absolute encoders are supported. The encoder pins are not exclusive to supporting encoders and have several functions available. The encoder inputs were isolated on a separate connector for wiring convenience. USB MCP IONMC.COM ERR STAT1 STAT2 CTRL ENC DRV Mating Connector Part Number: Pin NAME ENCODER ABSOLUTE UART TTL DIN ANALOG PULSE 1 +5V 2 GND 3 ENC1A Channel 1A (1) Channel 1 (1)(2) TX2 DIN17 AN8 P10 4 ENC2A Channel 2A (1) Channel 2 (1)(2) DIN18 AN9 P11 5 ENC1B Channel 1B (1) RX2 DIN19 AN10 P12 6 ENC2B Channel 2B (1) DIN20 AN11 P13 Notes: 1. Digital input pins are 15V tolerant. 2. Digital output pins can drive up to 3Amp at 40V. DOUT are low side driving pins. 3. Analog pins are 0V to 5.9V range. 4. I2C pins are 5V tolerant inputs with 3.3V compliant output. 5. Pulse inputs have a resolution of 12ns. (c) 2015 Ion Motion Control. All Rights Reserved. 6

7 Digital Driver (DRV) RoboClaw includes two general purpose 40V at 3Amp output for controlling brakes, contactors and other high load devices. The DRV pins in combination with a simple circuit can be used to regulate the regenerative function of RoboClaw allowing use of DC power supplies. The DRV pin functions can be defined using IonMotion PC utility. They can also be setup using packet serial commands. See RoboClaw User Manual for examples. USB MCP IONMC.COM ERR STAT1 STAT2 CTRL ENC DRV Mating Connector Part Number: Pin PWR DIN DOUT ANALOG PULSE ENCODER UART TTL UART RS232 CAN I2C 1 DOUT1 2 DOUT2 3 DOUT3 4 DOUT4 5 DOUT5 6 DOUT6 7 DOUT7 8 DOUT8 9 +5V 10 GND Notes: 1. Digital input pins are 15V tolerant. 2. Digital output pins can drive up to 3Amp at 40V. DOUT are low side driving pins. 3. Analog pins are 0V to 5.9V range. 4. I2C pins are 5V tolerant inputs with 3.3V compliant output. 5. Pulse inputs have a resolution of 12ns. (c) 2015 Ion Motion Control. All Rights Reserved. 7

8 Wiring Basics MCP must be wired correctly to ensure safe and reliable operation. The wiring diagram below illustrates one of several possible wiring configurations. An external main power cut off solution should be incorporated for safety. Regeneration will occur if the motors are moved when the system is off causing possible erratic behavior. Use a high current diode (D1) to create a return path to ground when the unit is switched off. Use a precharge resistor (R1) to avoid high inrush currents and arcing. A precharge resistor (R1) should be 1K, 2Watt for a 80VDC motor controller which will give a precharge time of about 15 seconds. A lower resistances can be used with lower voltages to decrease the precharge time. Wiring Closed Loop Mode A wide range of sensors for closed loop modes are supported including absolute, quadrature, potentiometers and hall effect sensor. The illustration below is an example of the wiring required for closed loop mode using quadrature encoders. Quadrature encoders are directional. The internal hardware counter will increment and decrement based on the direction of spin. When wiring encoders it is important they are wired to match the direction of the motor. If the encoder is wired in reverse it can cause a run away condition. Wiring Diagram Several wiring configurations are possible depending on the type of input or output being used. See the User Manual for additional examples. UART TX UART RX RX0 TX0 M1A 5VDC GROUND +5V GROUND Motor 1 MCU MCP M1B R1 B+ Encoder 1 A B GND +5V EN1 A EN1 B GROUND 5VDC M2B B- F1 D1 Encoder 2 A B GND +5V EN2 A EN2 B GROUND 5VDC Motor M2A Battery (c) 2015 Ion Motion Control. All Rights Reserved. 8

9 Logic Battery An optional logic battery supply is supported. Under heavy loads the main power can suffer voltage drops, causing potential logic brown outs which may result in uncontrolled behavior. A separate power source for the motor controllers logic circuits, can remedy potential problems from main power voltage drops. The logic battery maximum input voltage is 12VDC with a minimum input voltage of 6VDC. The 5V regulated user output is supplied by the secondairy logic battery if supplied. The mah of the logic battery should be determined based on the load of attached devices powered by the regulated 5V user output. R1 M1A B+ SW1 Motor 1 B- M1B MCP F1 D1 - + Battery M2B Motor 2 LB+ SW2 M2A GND F2 - + Logic Battery (c) 2015 Ion Motion Control. All Rights Reserved. 9

10 Contactors, Relays and Solenoids As a safety precaution an external power disconnect device should be used. A discconect such as a contactor, relay or solenoid with the proper ratings for the planned load. The disconnect devices contacts should be rated for the total current output of both motor channels combined. The disconnect device can be controlled by the DOUT pins or a simple manual switch. The DOUT pins are designed to control inductive loads. They can be toggled by users programs. The wiring diagram below illustrates a basic wire scheme using a relay as a disconnect for the main power. The DOUT controls the ground to the relay coil. The positive terminal of the relay coil can be connected several ways depending on its rated voltage. The diagram below shows a 12VDC logic battery and a 12VDC Rleay. If the relay coil is 5VDC the regulated user output (BEC) could be used instead. The main battery can also be the power source provided a logic battery is present. M1A Motor 1 M1B MCP M2B Motor 2 LB+ RY1 DOUT M2A B+ SW2 LB+ R1 GND B- F2 F1 D Logic Battery Battery (c) 2015 Ion Motion Control. All Rights Reserved. 10

11 Status and Error LEDs The MCP motor controller has three LEDs for in field diagnostic. Two status LEDs labeled STAT1 and STAT2 and an error LED labeled ERR. When the motor controller is first powered on all 3 LEDs should flash briefly to indicate all LEDs are functional. The LEDs will behave differently depending on the mode. During normal operation the status 1 LED will remain on continuously or blink when data is received in RC Mode or Serial Modes. The status 2 LED will light when either drive stage is active. USB MCP IONMC.COM ERR STAT1 STAT2 CTRL ENC DRV Error and Warning States When an error occurs both motor channel outputs will be disabled and RoboClaw will stop any further actions until the unit is reset, or in the case of non-latching E-Stops, the error state is cleared. When warnings occur both motor channel outputs will be controlled automatically depending on the warning condition(s). LED Status Condition Type Description All three LEDs lit. E-Stop Error Motors are stopped by braking. Error LED lit while condition is active. Error LED blinks once with short delay. Other LEDs off. Error LED lit while condition is active. Error LED blinking twice. STAT1 or STAT2 indicates channel. Error LED blinking three times. Over 85 C Temperature Warning Motor current limit is recalculated based on temperature. Over 100 C Temperature Error Motors freewheel while condition exist. Over Current Warning Motor power is automatically limited. Driver Fault Error Motors freewheel. MCP has detected damage. Logic Battery High Error Motors freewheel until MCP is reset. Error LED blinking four times. Logic Battery Low Error Motors freewheel until MCP is reset. Error LED blinking five times. Main Battery High Error Motors are stopped by braking until MCP is reset. Error LED lit while condition is active. Error LED lit while condition is active. Error LED lit while condition is active. Main Battery High Warning Motors are stopped by braking while condition exist. Main Battery Low Warning Motors freewheel while condition exist. M1 or M2 Home Warning Motor is stopped and encoder is reset to 0 (c) 2015 Ion Motion Control. All Rights Reserved. 11

12 Firmware Update LED State If all three LEDs begin to cycle on and off after powering on, the MCP has successfully been set to receive new firmware. Use IonMotion on a Windows PC to install the new firmware to clear this state. Automatic Battery Detection on Startup If the automatic battery detection mode is enabled the Stat2 LED will blink to indicate the detected battery type. Each blink indicates the number of LIPO cells detected. If automatic detection is used the number of cells detected should be confirmed on power up before running the unit. Undercharged or overcharged batteries can cause invalid auto detection. (c) 2015 Ion Motion Control. All Rights Reserved. 12

13 Bridging Channels The MCPs dual channels can be bridge to run as one channel, effectively doubling its current capability for one motor. Damage will result if the MCP is not set to bridged channel mode before wiring. Download and install IonMotion PC utility. Connect the motor controller to the computer using an available USB port. Run IonMotion and in general settings check the option to combine channels. When operating in bridged channel mode the total peak current output can be 240 / 320 / 400 amps depending on the model. The peak current run time is dependant on internal heat build up. Adequate cooling must be maintained. Bridged Channel Wiring When bridged channel mode is active the internal driver scheme for the output stage is modified. The output leads must be wired correctly or damage will result. Motor wire M1B is connected to M1A to create one side of the bridged driver. Motor wire M2A is connected to M2B to create the other side of the bridged driver. M2B B+ M1B M2A B- M1A MOTOR (c) 2015 Ion Motion Control. All Rights Reserved. 13

14 Motion Control Language The MCP motor controller can be customized using a built in programming language. The programming language is modeled after BASIC. The MCP motor controller can operate in standalone mode without additional external control. Several user I/O and operational parameters are directly accessible from user programs. The MCP includes IonMotion which is a free PC utility to create and download user programs to the motor controller. Programming Specifications Characteristic Model Min Typ Max Rating User Program Memory All 128 KBytes User Variable Memory All 16 KBytes User Program Execution Speed All 100,000 Lines/s Analog to Digital Resolution All 12 Bits System Clock Resolution All 32 Bits Microsecond Clock Resolution All 32 Bits Millisecond Clock Resolution All 32 Bits Uart Buffer All 256 Bytes Subroutine Nesting 256 Levels (c) 2015 Ion Motion Control. All Rights Reserved. 14

15 Mechanical Specifications Characteristic Model Min Typ Max Rating Weight All 68 (1927) Oz (g) Motor / Battery Wire Shipping Length All 17 (432) in (mm) Motor / Battery Wire Shipping Diameter All (8.6) in (mm) Dimensions 8.1 (205.7mm) 4.9 (124.5mm) 1.6 (40.6mm) 1.6 (40.6mm) 7.7 (196mm) (4.5mm) 1.95 (49.5mm) (c) 2015 Ion Motion Control. All Rights Reserved. 15

16 Electrical Specifications Characteristic Model Min Typ Max Rating Main Battery at 25 C MCP2xx VDC MCP2xx VDC MCP2xx VDC Regeneration Voltages All 100 VDC Reverse Voltage All -1 VDC Logic Battery All VDC Current Per Channel MCP212x 90 (3) 120 (1,2,3) A MCP216x 120 (3) 160 (1,2,3) A MCP220x 160 (3) 200 (1,2,3) A Current Bridged Channel MCP212x 180 (3) 240 (1,2,3) A MCP216x 240 (3) 320 (1,2,3) A MCP220x 320 (3) 400 (1,2,3) A On Resistance MCP212x 1.85 mohm MCP216x 1 mohm MCP220x 1 mohm User Current (BEC) All 3 A Logic Circuit Idle Current Draw All 90mA ma DIN Input Impedance All 1.2 K Ω I2C Input Impedance All 100 Ω I2C Input All 0 5 VDC DIN Input All 0 15 VDC DIN Input Low All VDC DIN Input High All VDC DOUT Max Current All 1 A DOUT Mav Voltage All 30 VDC DOUT Short Circuit Threshold All 3.5 A I/O Output Voltage All VDC Analog Input Voltage All 15 VDC Analog Useful Range All VDC Analog Resolution All 1.25 mv Pulse In Resolution All 12 ns Encoder Counters All 32 Bits Encoder Frequency All 21 Mhz RS232 Baud Rate All 921,600 Bits/s RS232 Time Out All 10 ms RS232 Max Voltage All VDC Temperature Operating Range All C Thermal Protection Range All C Notes: 1. Peak current is automatically reduced to the typical current limit as temperature approaches 85 C. 2. Motor Controller mounting and ventilation will affect maximum current. 3. Current is limited by maximum temperature. Starting at 75 C, the current limit is reduced on a slope with a maximum temperature of 90 C, which will reduce the current to 0 amps. Current ratings are based on ambient temperature of 25 C. 4. RS232 format is 8Bit, No Parity and 1 Stop bit. 5. Condensing humidity will damage the motor controller. (c) 2015 Ion Motion Control. All Rights Reserved. 16

17 Warranty Ion Motion Control warranties its products against defects in material and workmanship for a period of 1 year. If a defect is discovered, Ion Motion Control will, at our discretion, repair, replace, or refund the purchase price of the product in question. Contact us at sales@ionmc.com. No returns will be accepted without the proper authorization. Copyrights and Trademarks Copyright 2015 by Ion Motion Control, Inc. All rights reserved. All referenced trademarks mentioned are registered trademarks of their respective holders. Disclaimer Ion Motion Control cannot be held responsible for any incidental or consequential damages resulting from use of products manufactured or sold by Ion Motion Control or its distributors. No products from Ion Motion Control should be used in any medical devices and/or medical situations. No product should be used in a life support situation. Contacts sales@ionmc.com Tech support: support@ionmc.com Web: Discussion List A web based discussion board is maintained at Technical Support Technical support is available by sending an to support@ionmc.com, by opening a support ticket on the Ion Motion Control website or by calling during normal operating hours. All will be answered within 48 hours. (c) 2015 Ion Motion Control. All Rights Reserved.